A blade parts processing method capable of protecting machine tools and cutting tools

Abstract

The present invention discloses a method for processing blade parts that can protect machine tools and cutting tools, and relates to the field of blade part processing. The main steps are as follows: cutting the blade for the first time to obtain characteristic parameters of the cutting process, which are initial parameters; determining the rotation angle range corresponding to different cutting volumes of the blade based on the initial parameters; determining the program segment for processing the corresponding rotation angle range in the machine tool based on each rotation angle range; adjusting the cutting parameters in the program segment to change the characteristic parameters of the cutting process to within a set proportional range of the average value of the initial parameters; the machine tool cuts the blade multiple times; repeating the above steps to complete the processing of the blade; using this method to process the blade can effectively reduce the cutting force fluctuation, cutting vibration and impact generated by cyclic uneven cutting during the processing process, thereby achieving the purpose of protecting the machine tool and cutting tool.

Description

Technical Field

[0001] The invention relates to the field of blade part processing, in particular to a blade part processing method capable of protecting machine tools and cutting tools. Background Art

[0002] The feed system and spindle system are essential components of high-end CNC machine tools. Their operational stability and positioning accuracy are crucial for ensuring machining quality and efficiency. The mechanical transmission structure of a CNC machine tool feed system primarily consists of a servo motor, coupling, ball screw, rolling bearings, and guideways. The spindle, consisting primarily of a spindle box, spindle motor, bearings, and seals, is a core component of a CNC machine tool and directly impacts its performance and machining accuracy. Rolling bearings primarily support the spindle, bearing radial and axial forces, and supporting the ball screw. Wear is the most common type of failure, increasing the clearance between the bearing rolling elements and the inner and outer raceways, reducing bearing accuracy and resulting in reduced spindle system rotational accuracy and feed system travel or rotational accuracy. Ball screws are subject to long-term high loads and high speeds, making them susceptible to wear and bending, affecting feed smoothness and potentially causing motor overload and slip. Cracks in the coupling or loose screws can cause transmission asynchrony or even interference with the worktable. Insufficient lubrication or excessive load on the guide rails can damage the rail surface, resulting in poor slider movement and creep.

[0003] When machining blade-type parts made of difficult-to-machine materials such as high-strength stainless steel, titanium alloy, and high-temperature alloys, the high cutting forces, high cutting temperatures, and severe tool wear during the cutting of these materials, combined with the varying volume of material being cut during the blade's 360-degree rotation, lead to large fluctuations in cutting forces, significant impact, and significant cutting vibration. Uneven cyclic cutting can exacerbate wear on the spindle and feed system bearings, as well as wear and bending of the ball screw pair. This can lead to reduced spindle system rotation accuracy, reduced feed system movement or rotation accuracy, and even premature failure of key components such as bearings, ball screw pairs, and guide rails. Furthermore, uneven cyclic cutting can exacerbate tool wear and breakage, reducing tool life, increasing tool usage costs, lowering production efficiency, and increasing tool replacement time.

[0004] Therefore, a new processing method for blade parts is needed. Summary of the Invention

[0005] The purpose of the present invention is to provide a blade parts processing method that can protect machine tools and cutting tools in response to the above-mentioned problems. When processing blades, it can effectively reduce the cutting force fluctuations, cutting vibrations and impacts caused by cyclic uneven cutting during the processing process, so as to achieve the purpose of protecting key components of machine tools, extending the service life of machine tools, reducing tool wear and breakage, increasing tool service life, reducing tool use costs, improving production efficiency, and reducing tool replacement time.

[0006] The technical solution adopted by the present invention is as follows: a blade part processing method capable of protecting machine tools and cutting tools, comprising the following steps:

[0007] S1: Select appropriate machining centers and cutting parameters based on the shape, size, and precision requirements of the blades, and clamp the blades on the rotating axis of the machining center. For blades with complex shapes and high precision requirements, such as aircraft engine blades and gas turbine blades, a five-axis machining center can be selected. For applications with high machining efficiency, such as mass-produced blades, a 4+2-axis machine tool can be selected. For titanium alloy and high-temperature alloy blades, because titanium alloys and high-temperature alloys have high strength, low thermal conductivity, and work hardening properties, the machining process is prone to large cutting forces and high cutting temperatures, which affects machining efficiency and surface quality. Therefore, the parameters for rough machining can be: cutting speed 50-150m / min, feed rate 0.1-0.2mm / tooth, and cutting depth 1-3mm. The parameters for fine machining can be: cutting speed 80-200m / min, feed rate 0.15mm / tooth, and cutting depth 0.5mm. Of course, for other materials and high-temperature alloys, the cutting speed can be optimized to 20-50m / min.

[0008] S2: Start the rotating shaft, and the rotating shaft rotates the blade for at least one circle. At the same time, the tool cuts the blade and obtains the characteristic parameters of the cutting process, which are the initial parameters. Preferably, it is one circle. Of course, it can also rotate more circles, as long as the characteristic parameters of the cutting within 360° on the blade can be fully obtained.

[0009] S3: Determine the rotation angle range corresponding to different cutting volumes of the blade based on the initial parameters; within the same or similar cutting volume range, the angle at which the rotation axis rotates is the rotation angle range; specifically, if the initial parameter value is at a peak position, the corresponding cutting volume is larger; if the initial parameter value is at a trough position, the corresponding cutting volume is smaller or no material is cut.

[0010] S4: Determine the program segment for processing the corresponding rotation angle range in the machine tool according to each rotation angle range.

[0011] S5: Adjust the cutting parameters in the program segment so that the characteristic parameters of the cutting process are changed to within the set proportional range of the average value of the initial parameters; specifically, for the rotation angle range at the peak, the characteristic parameters of the material on the cutting blade in the rotation angle range can be reduced by reducing the cutting parameter values, such as the spindle speed, the tool feed speed, the cutting width, the cutting depth and the rotation speed of the rotating shaft; for the rotation angle range at the trough, the characteristic parameters of the material on the cutting blade in the rotation angle range can be increased by increasing the cutting parameter values, such as the spindle speed, the tool feed speed, the cutting width, the cutting depth and the rotation speed of the rotating shaft; thereby reducing the cutting force fluctuations and the cutting vibration and impact degree changes generated by the uneven cutting within the 360° range of the blade, thereby achieving the purpose of protecting key components of the machine tool, extending the service life of the machine tool, reducing tool wear and breakage, increasing tool service life, reducing tool use costs, improving production efficiency, and reducing tool replacement time.

[0012] S6: The machine tool cuts the blade multiple times, and the cutting parameters of each cutting are the cutting parameters in step S5; its main purpose is to increase or decrease the cutting parameters of the blade material in a certain rotation angle range.

[0013] S7: After completing step S6, the rotation angle range corresponding to different cutting volumes of the blade will change. Using the characteristic parameters obtained by the last cutting in step S6 as initial parameters, repeat steps S3-S6 to complete the processing of the blade.

[0014] Furthermore, in step S1, the processing machine tool is a processing machine tool with a spindle, that is, a five-axis processing machine tool is preferably used, which can complete multi-faceted processing of the blade at one time, reduce the number of clamping times, improve processing efficiency, and at the same time can realize the processing of the blade with high precision, and can ensure the surface accuracy and dimensional accuracy of the blade.

[0015] Furthermore, in step S2, the characteristic parameters include one or more of cutting force, torque, bending moment, and spindle current.

[0016] Furthermore, in step S2, sensors are installed on the tool holder or rotating shaft of the tool to obtain the cutting force, torque, and bending moment among the characteristic parameters, such as strain gauges; or a tool holder or rotating shaft with the function of obtaining the cutting force, torque, and bending moment among the characteristic parameters is used.

[0017] Furthermore, in step S2 , the processing machine tool directly obtains the current driving the spindle to rotate in the control system as the spindle current.

[0018] It should be noted that no matter which method is used to obtain the characteristic parameters, it is known to those skilled in the art. At the same time, the method of obtaining the characteristic parameters is not the focus of the disclosed solution of the present invention, so it will not be described in detail in this specification.

[0019] Furthermore, in step S5, the cutting parameters include any one or more of the spindle speed, the tool feed speed, the cutting width, the cutting depth and the rotation speed of the rotary axis.

[0020] Furthermore, in step S5, the set ratio range is 90%-110%, that is, within the range of 10% above and below the average value; we found that changing the characteristic parameter to within the range of ±10% of the average value of the initial parameter can achieve an effective balance between efficiency and protection of tools and machine tools; specifically, if the characteristic parameter changes to below this range, such as only reaching 50% of the average value, then its efficiency is lacking; if the characteristic parameter changes to above this range, such as reaching 150% of the average value, the characteristic parameter value is large, and the protection of tools and machine tools is lacking.

[0021] Furthermore, in step S6, the number of cutting times does not exceed 10 times.

[0022] Furthermore, in step S6, the number of cutting times is uncertain, and the characteristic parameters obtained during cutting are used to determine the rotation angle range corresponding to different cutting volumes of the blade. If the current rotation angle range changes by more than 5% compared to the rotation range determined by the initial parameters, the machine tool completes multiple cutting of the blade.

[0023] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are:

[0024] The present invention obtains the rotation angle range corresponding to different cutting volumes of the blade, and adjusts the cutting parameters according to the rotation angle range, so that in the subsequent cutting process, the characteristic parameters of the corresponding rotation angle range during cutting are changed to within the set proportional range of the average value of the initial parameters, thereby effectively reducing the cutting force fluctuations and cutting vibration and impact levels caused by cyclic uneven cutting during the processing process, thereby achieving the purpose of reducing tool wear and breakage, increasing tool service life, reducing tool use costs, improving production efficiency, and reducing tool replacement time, as well as reducing the degree of damage to key components such as bearings, ball screw pairs, guide rails on the machine tool, while protecting the machine tool and extending its service life. DETAILED DESCRIPTION

[0025] In the description of this manual, it should be noted that if the terms "center", "up", "down", "left", "right", "vertical", "horizontal", "inside", "outside" and so on appear to indicate the orientation or position relationship, they are based on the orientation or position relationship shown, or the orientation or position relationship in which the product of this manual is usually placed when used. They are only for the convenience of describing this manual and simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, they should not be understood as a limitation on this manual.

[0026] Furthermore, the use of terms such as "horizontal" and "vertical" in this specification does not necessarily imply that a component must be absolutely horizontal or suspended, but rather that it can be slightly tilted. For example, "horizontal" simply refers to a direction that is more horizontal than "vertical," and does not imply that the structure must be completely horizontal, but rather that it can be slightly tilted.

[0027] In the description of this specification, it should also be noted that, unless otherwise clearly stipulated and limited, the terms "setting", "installation", "connection" and "connection" should be understood in a broad sense. For example, the connection can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, or it can be a connection between the internal parts of two components.

[0028] Example

[0029] A method for processing blade parts that can protect machine tools and cutting tools, taking the processing of titanium alloy blade parts as an example, includes the following steps:

[0030] S1: Select a suitable processing machine tool and cutting parameters based on the blade, and clamp the blade on the rotating axis of the processing machine tool; the processing machine tool is a five-axis processing machine tool with a spindle, the tool is a 25mm diameter carbide end mill, and the cutting parameters are: speed 380r / min-800r / min, feed 450mm / min-720mm / min, cutting width 8mm-12.5mm, and cutting depth 0.8mm-1.5mm.

[0031] S2: Start the rotating shaft, and rotate the blade with the rotating shaft for at least one revolution. At the same time, the tool cuts the blade with the cutting parameters in step S1, and obtains characteristic parameters of the cutting process, which are initial parameters.

[0032] The characteristic parameters include one or more of cutting force, torque, bending moment, and spindle current;

[0033] Installing sensors on the tool holder or rotating shaft of the tool to obtain the cutting force, torque, and bending moment among the characteristic parameters; or using a tool holder or rotating shaft with the function of obtaining the cutting force, torque, and bending moment among the characteristic parameters;

[0034] The current driving the spindle rotation in the control system is directly obtained through the processing machine as the spindle current;

[0035] In this embodiment, the characteristic parameter is selected as bending moment, which is obtained by a wireless force measuring tool handle; the obtained bending moment has a peak value of 42 Nm, a trough value of -14 Nm, and an average value of 28 Nm.

[0036] S3: Determine the rotation angle range corresponding to the different cutting volumes of the blade based on the initial parameters. Of course, when the blade rotates one circle, there are multiple rotation angle ranges within its 360° range. Each rotation angle range corresponds to a different cutting volume. The size of the range is reflected according to the specific value of the characteristic parameter. For example, the numerical value difference within ±10% can be considered to be the same cutting volume, that is, the rotating shaft rotates with the blade, and the tool cuts the same cutting volume. The angle of rotation of the rotating shaft is the rotation angle range. Specifically, when the rotating shaft rotates with the blade, if the characteristic parameter generated when the tool cuts the blade is 20.68Nm-22.74NM, it can be considered that the volume cut by the tool is the same cutting volume, and the corresponding rotation axis angle is 30°-40°, then the rotation angle range is 30°-40°; for example, when the tool cuts the blade, the characteristic parameter generated when the tool cuts the blade is 35.43Nm-42.00NM, it can be considered that the volume cut by the tool is the same cutting volume, and the corresponding rotation axis angle is 225°-250°, then the rotation angle range is 225°-250°.

[0037] S4: Determine the program segments in the machine tool that process the corresponding rotation angle ranges according to the rotation angle ranges, such as finding the program segments in which the rotation axis rotates 30°-40° and 225°-250°.

[0038] S5: Adjust the cutting parameters in the program segment so that the characteristic parameters of the cutting process are changed to the set ratio range of the average value of the initial parameters, and the set ratio range is 90%-110%; the adjusted cutting parameters include any one or more of the spindle speed, tool feed speed, cutting width, cutting depth and rotating axis speed.

[0039] In this embodiment, taking the average value of the characteristic parameter as 28Nm as an example, the bending moment value corresponding to the setting ratio range is 25.2Nm-30.8Nm; then the spindle speed, tool feed speed, cutting width, cutting depth and rotating shaft speed can be reduced to make the bending moment when cutting the material of the blade in the rotation angle range so that the bending moment is within the range of 25.2Nm-30.8Nm; further, the spindle speed can be adjusted by adjusting the power of the spindle motor, and the speed of the rotating shaft can be adjusted by adjusting the power of the rotating shaft motor.

[0040] S6: The machine tool performs multiple cutting operations on the blade, and the cutting parameters for each cutting are the cutting parameters in step S5;

[0041] The number of cutting times is usually no more than 20 times; or as the processing progresses, the rotation angle range on the blade changes, that is, the number of cutting times is uncertain, and the characteristic parameters obtained during cutting are used to determine the rotation angle range corresponding to different cutting volumes of the blade. If the current rotation angle range changes by more than 5% compared with the rotation range determined by the initial parameters, the machine tool has completed multiple cutting of the blade.

[0042] S7: Using the characteristic parameters obtained by the last cutting in step S6 as initial parameters, repeat steps S3-S6 to complete the processing of the blade.

[0043] Practice has found that, compared with the traditional processing method, the method disclosed in this embodiment can process the blades until the tool is damaged. For the same tool, the number of blades processed by the method disclosed in this embodiment has increased by 15%, and the time taken to complete the blade processing is only slightly lower than that of the traditional processing method, and the average time taken is 104% of the time taken to complete the blade processing by the traditional processing method. It can be seen from this that by obtaining the rotation angle range corresponding to the different cutting volumes of the blade, the cutting parameters are adjusted according to the rotation angle range, so that in the subsequent cutting process, the characteristic parameters of the corresponding rotation angle range during cutting are changed to the set proportion range of the average value of the initial parameters, thereby effectively reducing the cutting force fluctuations and cutting vibrations and impacts caused by the uneven cyclic cutting during the processing process, achieving the purpose of reducing tool wear and breakage, increasing tool life, reducing tool use costs, improving production efficiency, reducing tool replacement time, and reducing the degree of damage to key components such as bearings, ball screw pairs, guide rails on the machine tool, while protecting the machine tool and extending its service life.

[0044] The present invention is not limited to the aforementioned specific embodiments, but extends to any new features or any new combination disclosed in this specification, as well as any new method or process steps or any new combination disclosed.

Claims

1. A blade parts processing method capable of protecting machine tools and cutting tools, characterized in that: The following steps are involved: S1: Select a suitable processing machine tool and cutting parameters according to the blade, and clamp the blade on the rotating axis of the processing machine tool; S2: Start the rotating shaft, and the rotating shaft rotates the blade for at least one circle. At the same time, the tool cuts the blade and obtains characteristic parameters of the cutting process, which are the initial parameters. S3: Determine the rotation angle range corresponding to different cutting volumes of the blade according to the initial parameters; S4: Determine the program segment for machining the corresponding rotation angle range in the machine tool according to each rotation angle range; S5: Adjust the cutting parameters in the program segment so that the characteristic parameters of the cutting process are changed to within the set ratio range of the average value of the initial parameters; S6: The machine tool performs multiple cutting operations on the blade, and the cutting parameters for each cutting are the cutting parameters in step S5; S7: Using the characteristic parameters obtained by the last cutting in step S6 as initial parameters, repeat steps S3-S6 to complete the processing of the blade.

2. The blade parts processing method capable of protecting machine tools and cutting tools according to claim 1 is characterized in that: In step S1 , the processing machine tool is a processing machine tool having a main spindle.

3. The blade parts processing method capable of protecting machine tools and cutting tools according to claim 2 is characterized in that: In step S2 , the characteristic parameters include one or more of cutting force, torque, bending moment, and spindle current.

4. The blade parts processing method capable of protecting machine tools and cutting tools according to claim 3 is characterized in that: In step S2, sensors are installed on the tool holder and rotating shaft of the tool to obtain the cutting force, torque and bending moment among the characteristic parameters; or a tool holder and rotating shaft with the function of obtaining the cutting force, torque and bending moment among the characteristic parameters are used.

5. The blade parts processing method capable of protecting machine tools and cutting tools according to claim 3 is characterized in that: In step S2 , the processing machine tool directly obtains the current driving the main spindle to rotate in the control system as the main spindle current.

6. The blade parts processing method capable of protecting machine tools and cutting tools according to claim 2, characterized in that: In step S5 , the cutting parameters include any one or more of the spindle speed, the tool feed rate, the cutting width, the cutting depth, and the rotation speed of the rotary axis.

7. The blade parts processing method capable of protecting machine tools and cutting tools according to claim 2, characterized in that: In step S5, the setting ratio range is 90%-110%.

8. The blade parts processing method capable of protecting machine tools and cutting tools according to claim 2, characterized in that: In step S6, the number of cutting times does not exceed 10 times.

9. The blade parts processing method capable of protecting machine tools and cutting tools according to claim 2, characterized in that: In step S6, the number of cutting times is uncertain, and the characteristic parameters obtained during cutting are used to determine the rotation angle range corresponding to different cutting volumes of the blade. If the current rotation angle range changes by more than 5% compared to the rotation range determined by the initial parameters, the machine tool has completed multiple cutting of the blade.